EESG 09101: Sustainable Conventional Energy Systems

LECTURE 4
COGENERATION (TPC PLANT)
Objectives

1. Analyze power generation coupled with process heating called

cogeneration.

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BAGASSE POWER COGENERATION IN SUGAR
MILL

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4
COGENERATION (TPC PLANT)
 In all the cycles discussed so far, the sole purpose was to convert a
portion of the heat transferred to the working fluid to work, which is
the most valuable form of energy.
 The remaining portion of the heat is rejected to rivers, lakes,
oceans, or the atmosphere as waste heat, because its quality (or
grade) is too low to be of any practical use.
 Wasting a large amount of heat is a price we have to pay to
produce work, because electrical or mechanical work is the only
form of energy on which many engineering devices (such as a fan)
can operate

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COGENERATION (TPC PLANT)
 Many systems or devices, however, require energy input in the
form of heat, called process heat.
 Some industries that rely heavily on process heat are chemical,
pulp and paper, oil production and refining, steel making, food
processing, and textile industries.
 Process heat in these industries is usually supplied by steam at 5
to 7 atm and 150 to 200°C (300 to 400°F).
 Energy is usually transferred to the steam by burning coal, oil,
natural gas, or another fuel in a furnace (e.g bagasse).

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ANALYSIS OF COGENERATION
 Disregarding any heat losses in the piping, all the heat transferred
to the steam in the boiler is used in the process-heating units.
 Therefore, process heating seems like a perfect operation with
practically no waste of energy.
 The temperature in furnaces is typically very high (around 1400°C),
and thus the energy in the furnace is of very high quality.
 This high-quality energy is transferred to water to produce steam at
about 200°C or below (a highly irreversible process).
 Associated with this irreversibility is, of course, a loss in exergy or
work potential.
 It is simply not wise to use high-quality energy to accomplish a task
that could be accomplished with low-quality energy.
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ANALYSIS OF COGENERATION
 Industries that use large amounts of process heat also consume a
large amount of electric power.
 Therefore, it makes economical as well as engineering sense to
use the already-existing work potential to produce power instead of
letting it go to waste.
 The result is a plant that produces electricity while meeting the
process-heat requirements of certain industrial processes.
 Such a plant is called a cogeneration plant.

 In general, cogeneration is the production of more than one useful

form of energy (such as process heat and electric power) from the
same energy source.

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WHAT IS COGENERATION?
 Cogeneration is the production of electrical energy
and another form of useful energy, such as heat or
steam, through the sequential use of energy.
 Cogeneration is also often referred to as
Combined Heat and Power or “CHP”.
 In the USA and the continental European
Community countries, CHP is sometimes referred
to as “total energy” or as “cogeneration”
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COGENERATION
 Combined Heat and Power (CHP) is a simple concept
which involves a cost-efficient means of generating both
electrical and thermal energy from the same fuel source.
 A CHP is an installation where there is simultaneous
generation of usable heat and power (usually electricity) in
a single process.
 High temperature heat from fuel combustion is used to
generate electricity while lower temperature exhaust heat
can be used for industrial process heat, district heating
and space heating.
COGENERATION

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COGENERATION
 Cogeneration plants can be used in all situations where a
given heat demands exists.
 Cogeneration technologies;
 Gas Engines
(Fig. 9-21)
 Gas turbines
 The stirling engine
FIVE PRINCIPAL TYPES OF CHP
SYSTEMS
 There are five principal types of CHP systems;
(a) Back pressure steam turbine systems
(b) Pass-out condensing steam turbine systems
(c) Gas turbine systems,
(d) Reciprocating engine systems,
(e) Combined-cycle systems,
BACK PRESSURE STEAM TURBINE
SYSTEMS
 in which high pressure steam is generated in a
boiler and wholly or partly used in a steam turbine–
generator system.
 Lower pressure exhaust steam can be extracted at
an appropriate site pressure.
 It is possible to extract some proportion of the
steam used by the turbine at an intermediate
pressure, giving rise to the name pass-out/back
pressure steam turbine.
PASS-OUT CONDENSING STEAM TURBINE
SYSTEMS
 in which a proportion of the exhaust steam used by
the turbine is extracted at an intermediate
pressure.
 The remaining exhaust steam is fully condensed to
hot water before being exhausted.
 This system is called a pass-out/condensing steam
turbine.
GAS TURBINE SYSTEMS
 inwhich fuel is combusted in a gas turbine and
the exhaust gases are used to supply a waste
heat boiler producing usable heat.
 Some exhaust gases may be used directly for
process heat applications.
RECIPROCATING ENGINE SYSTEMS
 whichproduce two grades of waste heat: high
grade heat from the engine exhaust and low
grade heat from the engine cooling circuits.
COMBINED-CYCLE SYSTEMS
 where the exhaust gases from a gas turbine
are used to power a steam turbine for conjoint
electricity generation.
 Some further discussion of this is given below
ANALYSIS OF COGENERATION
 Industries that use large amounts of process heat also consume a
large amount of electric power.
 Therefore, it makes economical as well as engineering sense to
use the already-existing work potential to produce power instead of
letting it go to waste.
 The result is a plant that produces electricity while meeting the
process-heat requirements of certain industrial processes.
 Such a plant is called a cogeneration plant.

 In general, cogeneration is the production of more than one useful

form of energy (such as process heat and electric power) from the
same energy source.

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ANALYSIS OF COGENERATION

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UTILIZATION FACTOR
 Probably the most striking feature of the ideal steam-turbine
cogeneration plant shown in Fig. 10–21 is the absence of a
condenser.
 Thus no heat is rejected from this plant as waste heat. In other
words, all the energy transferred to the steam in the boiler is
utilized as either process heat or electric power.
 Thus it is appropriate to define a utilization factor u for a
cogeneration plant as
Net Work Out  Process heat delivered
u 
Total Heat Input
 
W net  Q p
u  
Q in

Q out 21
u  1 
Q in
UTILIZATION FACTOR
 where Qout represents the heat rejected in the condenser.
 Strictly speaking, Qout also includes all the undesirable heat losses
from the piping and other components, but they are usually small
and thus neglected.
 It also includes combustion inefficiencies such as incomplete
combustion and stack losses when the utilization factor is defined
on the basis of the heating value of the fuel.
 The utilization factor of the ideal steam-turbine cogeneration plant is
obviously 100 percent.
 Actual cogeneration plants have utilization factors as high as 80
percent.
 Some recent cogeneration plants have even higher utilization
factors 22
A COGENERATION PLANT WITH ADJUSTABLE
LOADS
 The ideal steam-turbine cogeneration
plant described above is not practical
because it cannot adjust to the
variations in power and process-heat
loads.
 The schematic of a more practical (but
more complex) cogeneration plant is
shown in Fig. 10–22.

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A COGENERATION PLANT WITH ADJUSTABLE
LOADS
 Under normal operation, some steam is
extracted from the turbine at some
predetermined intermediate pressure P6.
 The rest of the steam expands to the
condenser pressure P7 and is then cooled
at constant pressure.
 The heat rejected from the condenser
represents the waste heat for the cycle.

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A COGENERATION PLANT WITH ADJUSTABLE
LOADS
 At times of high demand for process heat, all the steam is routed to

the process-heating units and none to the condenser ( m7  0 )
 The waste heat is zero in this mode.

 If this is not sufficient, some steam leaving the boiler is throttled by

an expansion or pressure-reducing valve (PRV) to the extraction
pressure P6 and is directed to the process-heating unit.
 Maximum process heating is realized when all the steam leaving the
 

boiler passes through the PRV ( m  m ) 5 4

 No power is produced in this mode.

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A COGENERATION PLANT WITH ADJUSTABLE
LOADS
 When there is no demand for process heat, all the steam passes
 
through the turbine and the condenser ( m  m  0 ), and the
5 6

cogeneration plant operates as an ordinary steam power plant

 The rates of heat input, heat rejected, and process heat supply as well
as the power produced for this cogeneration plant can be expressed
as follows:
 
Q in  m3 (h4  h3 )
 
Q out  m7 (h7  h1 )
   
Q p  m5 h5  m6 h6  m8 h8
   
W turb  (m4  m5 )(h4  h6 )  m7 (h6  h7 ) 26
A COGENERATION PLANT WITH ADJUSTABLE
LOADS
 Under optimum conditions, a cogeneration plant simulates the
ideal cogeneration plant discussed earlier.
 That is, all the steam expands in the turbine to the extraction
pressure and continues to the process-heating unit.
 No steam passes through the PRV or the condenser; thus, no
   
waste heat is rejected ( m  m and m  m  0).
4 6 5 7

 This condition may be difficult to achieve in practice because of

the constant variations in the process-heat and power loads.
 But the plant should be designed so that the optimum
operating conditions are approximated most of the time.
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A COGENERATION PLANT WITH ADJUSTABLE
LOADS
 The use of cogeneration dates to the beginning of this century when
power plants were integrated to a community to provide district
heating, that is, space, hot water, and process heating for residential
and commercial buildings.
 The district heating systems lost their popularity in the 1940s owing
to low fuel prices.
 However, the rapid rise in fuel prices in the 1970s brought about
renewed interest in district heating.
 Cogeneration plants have proved to be economically very attractive.

 Consequently, more and more such plants have been installed in

recent years, and more are being installed. 28
EXAMPLE 10–8 AN IDEAL COGENERATION
PLANT
Consider the cogeneration plant shown in Fig. 10–23. Steam enters the turbine at 7
MPa and 500°C. Some steam is extracted from the turbine at 500 kPa for process
heating. The remaining steam continues to expand to 5 kPa. Steam is then condensed
at constant pressure and pumped to the boiler pressure of 7 MPa. At times of high
demand for process heat, some steam leaving the boiler is throttled to 500 kPa and is
routed to the process heater. The extraction fractions are adjusted so that steam
leaves the process heater as a saturated liquid at 500 kPa. It is subsequently pumped
to 7 MPa. The mass flow rate of steam through the boiler is 15 kg/s. Disregarding any
pressure drops and heat losses in the piping and assuming the turbine and the pump
to be isentropic, determine (a) the maximum rate at which process heat can be
supplied, (b) the power produced and the utilization factor when no process heat is
supplied, and (c) the rate of process heat supply when 10 percent of the steam is
extracted before it enters the turbine and 70 percent of the steam is extracted from the
turbine at 500 kPa for process heating.
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SOLUTION FOLLOW EXAMPLE 10-8
 A cogeneration plant is considered.
 The maximum rate of process heat supply, the power produced
and the utilization factor when no process heat is supplied, and
the rate of process heat supply when steam is extracted from
the steam line and turbine at specified ratios are to be
determined.
 Assumptions
 1 Steady operating conditions exist.
 2 Pressure drops and heat losses in piping are negligible.
 3 Kinetic and potential energy changes are negligible.

 Analysis: The schematic of the cogeneration plant and the T-s

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diagram of the cycle are shown in Fig. 10–23.
SOLUTION

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SOLUTION
 The power plant operates on an idea cycle and thus the pumps and
the turbines are isentropic; there are no pressure drops in the boiler,
process heater, and condenser; and steam leaves the condenser
and the process heater as saturated liquid.
 The work inputs to the pumps and the enthalpies at various states
are as follows:

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COMBINED HEAT AND POWER
(CHP)
 In conventional electricity generation, by the use of
steam turbines, only 30–35% of the energy originally
available in fuel is converted to electricity.
 The remainder is converted to hot exhaust gases or to
hot water derived from cooling the turbine condensers
 If this waste heat can be used, thus saving on other
forms of heating, a large gain of overall efficiency can
be realised.
COGENERATION
 Decentralized combined heat and power production-cogeneration is a
very flexible and efficient way of utilizing fuels.
 A very large percentage of the fuel’s energy content is utilized,
typically 85-95%.

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COGENERATION PLANT
 A cogeneration plant is to generate power and process heat. Consider an ideal
cogeneration steam plant. Steam enters the turbine from the boiler at 7 MPa, 500
C and a mass flow rate of 30 kg/s. One-fourth of the steam is extracted from the
turbine at 600-kPa pressure for process heating. The remainder of the steam
continues to expand and exhausts to the condenser at 10 kPa. The steam extracted
for the process heater is condensed in the heater and mixed with the feedwater at
600 kPa. The mixture is pumped to the boiler pressure of 7 MPa. Show the cycle on
a T-s diagram with respect to saturation lines, and determine
a) the heat transfer from the process heater per unit mass leaving the boiler
Qdot, process = 15,774 kW.
b) the net power produced by the cycle. Wdot,net = 32,848 kW.
c) the utilization factor of the plant Qdot,in = 92,753 kW, Utilization factor =
52.4%. 35